Electrocatalytic energy conversion and chemicals production

Abstract

Oxidation reactions and unsaturation producing reactions are disclosed to be carried out in a solid-state electrocatalytic reactor for electrolytic energy conversion and chemicals production. Additional reactions are disclosed to be carried out in a solid-state electrocatalytic cross flow monolith which has a high ion transport surface area per reactor volume. The additional reactions include selected oxidation reactions, selected addition reactions, electrolysis of steam to hydrogen, decomposition of nitric oxide to nitrogen and oxygen and the manufacture of aluminum from Al 2 O 3 in a eutectic solution.

What is claimed is: 
     
       1. A method of electrocatalytic energy production and electrosynthesis of chemicals comprising reacting in a solid-state electrocatalytic cross flow monolith formed of an oxygen ion-conducting electrolyte and having a high ion transport surface area per reactor volume an electrochemical reaction selected from the group consisting of: A. oxidation reactions selected from the group consisting of sulfur to SO 2  or SO 3 ,   hydrogen sulfide to SO 2  or SO 3 ,   methanol to formaldehyde,   alcohols having 2 or more carbon atoms to their oxidized products,   paraffins to their oxidized products,   olefins to their oxidized products,   alkyl-aromatics to their oxidized products,   naphthalene to phthalic anhydride,   benzene to maleic anhydride,   butane to maleic anhydride, and   butene to maleic anhydride;     B. addition reactions selected from the group consisting of NH 3  +O 2  +CH 4  to HCN,   CO+H 2  to higher hydrocarbons,   CO+H 2  to partially oxidized hydrocarbons, and   CO+H 2  +olefins to higher hydrocarbons;     C. decomposition of NO to N 2  and O 2  ; and   D. manufacture of aluminum from Al 2  O 3  in a eutectic solution.   
     
     
       2. A method according to claim 1, wherein the electrochemical reaction comprises the addition reaction of CO+H 2  to higher hydrocarbons. 
     
     
       3. A method according to claim 1, wherein the electrochemical reaction comprises the addition reaction of CO+H 2  to partially oxidized hydrocarbons. 
     
     
       4. A method according to claim 1, wherein the electrochemical reaction comprises the addition reaction of CO+H 2  +olefins to higher hydrocarbons. 
     
     
       5. A method according to claim 1, wherein the electrochemical reaction comprises either the oxidation reaction of sulfur dioxide to SO 3  or the electrolysis of steam to H 2  and said solid-state electrocatalytic cross flow monolith comprises a plurality of stacked essentially planar parallel sheets of a fluid-impermeable solid electrolyte capable of transporting oxygen ions, each sheet possessing a plurality of parallel elongated channels separated by ribs, said sheets divided into first and second groups wherein the sheets of said groups are interposed in an alternate manner, the channels of said first group forming an angle with the channels of said second group, the channels of said first group having a catalytic, oxygen-dissociating material disposed therein and the channels of the second group having a catalyst for promoting oxidation reactions disposed therein and said reactor fitted with conductive means to transport electricity. 
     
     
       6. A method according to claim 1, wherein the electrochemical reaction comprises oxidation reactions selected from the group consisting of: ammonia to nitric oxide (NO),   hydrogen to water,   carbon monoxide to CO 2 , and   methanol to CO 2   and said solid-state electrocatalytic cross flow monolith comprises a plurality of stacked essentially planar parallel sheets of a fluid-impermeable solid electrolyte capable of transporting oxygen ions, each sheet possessing a plurality of parallel elongated channels separated by ribs, said sheets divided into first and second groups wherein the sheets of said groups are interposed in an alternate manner, the channels of said first group forming an angle with the channels of said second group, the channels of said first group having a catalytic, oxygen-dissociating material disposed therein and the channels of the second group having a catalyst for promoting oxidation reactions disposed therein and said reactor fitted with conductive means to transport electricity.     
     
     
       7. A method according to claim 5, wherein the electrochemical reaction comprises the oxidation reaction of ammonia to nitric oxide (NO). 
     
     
       8. A method according to claim 5, wherein the electrochemical reaction comprises the oxidation reaction of hydrogen to water. 
     
     
       9. A method according to claim 5, wherein the electrochemical reaction comprises the oxidation reaction of carbon monoxide to CO 2 . 
     
     
       10. A method of electrocatalytic energy production and electrosynthesis of chemicals comprising reacting in a solid-state electrocatalytic reactor having an oxygen ion-conducting electrolyte and electrochemical reaction selected from the group consisting of A. oxidation reactions selected from the group consisting of mono-olefins having 4 or more carbon atoms to form oxygenated products selected from the group consisting of epoxides, aldehydes, ketones, acids and anhydrides;   olefins with two or more double bonds and having 4 or more carbon atoms to form oxygenated products selected from the group consisting of epoxides, aldehydes, ketones, acids and anhydrides;   aliphatic compounds having 4 or more carbon atoms to form oxygenated products selected from the group consisting of epoxides, aldehydes, ketones, acids and anhydrides; and   fuels having 4 or more carbon atoms selected from the group consisting of mono-olefins, olefins with two or more double bonds and aliphatic compounds to form CO, CO 2  or H 2  O; and     B. unsaturation producing reactions selected from the group consisting of mono-olefins having 4 or more carbon atoms to form olefins having 2 or more double bonds;   ethane to form ethene;   aliphatic compounds having 4 or more carbon atoms to form olefins; and   alkyl aromatic compounds where the alkyl group has 3 or more carbon atoms to form the corresponding olefin-substituted aromatic compound.     
     
     
       11. A method according to claim 10, wherein the electrochemical reaction is conducted in a solid-state electrocatalytic cross-flow monolith.